Industrial two-layer fabric

Abstract

An industrial two-layer fabric includes an upper layer fabric including upper side warps and upper side wefts and a lower layer fabric including lower side warps and lower side wefts, and the upper layer fabric and the lower layer fabric are bound by warps that function as binding yarns. The industrial two-layer fabric, warp knuckles are formed on a surface side, and each warp knuckle is formed by allowing a warp to pass over a single upper side weft; in a shaft adjacent to the warp knuckle, at least two other warp knuckles are arranged in a diagonal direction in a planar view; and the warp knuckles are sequentially arranged in such a way as to form a herringbone pattern on a surface layer side of the fabric.

Claims

1. An industrial two-layer fabric comprising: an upper layer fabric including upper side warps and upper side wefts; and a lower layer fabric including lower side warps and lower side wefts, the upper layer fabric and the lower layer fabric being bound by warps that function as binding yarns, warp knuckles being formed on a surface side, each warp knuckle being formed by allowing a warp to pass over a single upper side weft, in a shaft adjacent to the warp knuckle, at least two other warp knuckles being arranged in a diagonal direction in a planar view, the warp knuckles being sequentially arranged in such a way as to form a herringbone pattern on a surface layer side of the fabric.

2. The industrial two-layer fabric according to claim 1, wherein a minimum number of the warp knuckles sequentially arranged between peaks forming the herringbone pattern is 3, and a maximum number of the sequentially arranged warp knuckles is twice a number of the upper side warps in a complete design.

3. The industrial two-layer fabric according to claim 1, wherein the warp knuckle arranged at the peak of the herringbone pattern is the binding yarn.

4. The industrial two-layer fabric according to claim 1, wherein all knuckles formed by the upper side wefts appearing on the surface side of the fabric have an equal length.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a design diagram illustrating a complete design of a first embodiment of an industrial two-layer fabric of the present invention.

(2) FIGS. 2 (a), (b) and (c) are schematic cross-sectional views of the first embodiment illustrated in FIG. 1 in the warp direction.

(3) FIG. 3 is a design diagram illustrating a complete design of a second embodiment of the industrial two-layer fabric of the present invention.

(4) FIGS. 4 (a), (b), (c), (d), (e) and (f) are schematic cross-sectional views of the second embodiment illustrated in FIG. 3 in the warp direction.

(5) FIG. 5 is a design diagram partly illustrating a surface pattern of a third embodiment of the industrial two-layer fabric of the present invention.

(6) FIG. 6 is a design diagram partly illustrating a surface pattern of a fourth embodiment of the industrial two-layer fabric of the present invention.

(7) FIG. 7 is a design diagram partly illustrating a surface pattern of a fifth embodiment of the industrial two-layer fabric of the present invention.

(8) FIG. 8 is a photograph illustrating the result of a surface printing mark test on the industrial two-layer fabric of the present invention.

(9) FIG. 9 is a photograph illustrating the result of a surface printing mark test on a conventional industrial two-layer fabric.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(10) An industrial two-layer fabric of the present invention will be described hereinafter in detail.

(11) The industrial two-layer fabric of the present invention includes two layers, an upper layer fabric including upper side warps and upper side wefts and a lower layer fabric including lower side warps and lower side wefts. The upper layer fabric and the lower layer fabric are bound by warps that function as binding yarns.

(12) The industrial two-layer fabric of the present invention is characterized in that warp knuckles are formed on the surface side, and each warp knuckle is formed by allowing a warp to pass over a single upper side weft. In shafts adjacent to the warp knuckle, at least two other warp knuckles are arranged in diagonal directions in a planar view, and the warp knuckles are sequentially arranged in such a way as to form a herringbone pattern on the surface layer side of the fabric.

(13) In the present invention, a single binding yarn forms a knuckle on the upper layer fabric, and at places adjacent to the knuckle, two warp knuckles are formed in diagonal directions. Thus, an uneven shape generated around a warp knuckle formed by a single binding yarn can be cancelled by the stress relation with two adjacent warp knuckles. Accordingly, dehydration marks of the fabric are suppressed to be transferred to paper, and consequently, the fabric can prevent transfer marks from forming on a contact face of the paper with the fabric and have good surface smoothness.

(14) The yarn used in the industrial two-layer fabric of the present invention can be selected depending on the purpose. The usable yarn is exemplified by monofilaments, multifilaments, spun yarns, finished yarns subjected to crimping or bulking, commonly called textured yarns, bulky yarns, and stretch yarns, and combination yarns prepared by intertwining them. As for the cross-section shape of the yarn, not only yarns having a circular shape but also yarns having a short shape such as a quadrangular shape and a star shape, yarns having an elliptical shape, and hollow yarns can be used. The raw material of the yarn can be freely selected, and usable examples include polyester, polyamide, polyphenylene sulfide, polyvinylidene fluoride, polypropylene, aramid, polyether ether ketone, polyethylene naphthalate, polytetrafluoroethylene, cotton, wool, and metals. Needless to say, yarns prepared from a copolymer and yarns prepared by blending or adding various substances to such a material can be used according to the purpose. For typical papermaking wires, polyester monofilaments having rigidity and excellent dimensional stability are preferably used as upper side warps, lower side warps, binding yarns, and upper side wefts. As lower side wefts required to have wear resistance, yarns are preferably interwoven to ensure the rigidity and to improve the wear resistance. For example, polyester monofilaments and polyamide monofilaments are alternately arranged.

(15) Embodiments of the industrial two-layer fabric of the present invention will next be described. The embodiments described below are merely examples of the present invention and are not intended to limit the present invention.

(16) Embodiments of the industrial two-layer fabric of the present invention will be described with reference to drawings. FIG. 1 to FIG. 7 are design diagrams illustrating first to fifth embodiments of the industrial two-layer fabric of the present invention. The complete designs shown below are the minimum repeating unit of a weave pattern, and the complete designs are connected vertically and horizontally to form the whole design of a fabric. In the design diagrams, warps are represented by Arabic numerals, for example, 1, 2, and 3. In the embodiments, the warps having a binding function are represented by b. Upper side warps are represented by U, and lower side warps are represented by L. Wefts are represented by Arabic numerals with a prime, for example, 1, 2, and 3. Depending on an arrangement ratio, upper side wefts and lower side wefts are vertically arranged in some cases, and only upper side wefts are arranged in some cases. Upper side wefts are represented by U, and lower side wefts are represented by L.

(17) The mark X indicates that an upper side warp is positioned over an upper side weft; the mark .circle-solid. indicates that a binding yarn is positioned over an upper side weft; the mark .box-tangle-solidup. indicates that a binding yarn is positioned under a lower side weft; and the mark indicates that a lower side warp is positioned under a lower side weft.

(18) Some upper side warps are vertically overlapped with some lower side warps, and some upper side wefts are vertically overlapped with some lower side weft. Depending on an arrangement ratio, no lower side weft is placed under some upper side wefts. In the design diagrams, yarns are exactly vertically overlapped, but this arrangement is for convenience of drawings. In an actual fabric, yarns may be displaced.

First Embodiment

(19) FIG. 1 is a design diagram illustrating a complete design of a first embodiment of the industrial two-layer fabric of the present invention. The design diagram includes an upper side warp (2U), a lower side warp (2L), and two warp pairs including upper side binding warps (1Ub, 3Ub) and lower side binding warps (1Lb, 3Lb) having a binding function. A first warp pair is composed of 1Ub and 1Lb, and a second warp pair is composed of 3Ub and 3Lb. As shown in FIG. 1, a pair of the upper side warp (2U) and the lower side warp (2L) is arranged between the first warp pair and the second warp pair to form a six-shaft fabric. The arrangement ratio of upper side wefts and lower side wefts is 4:3.

(20) Each of the warp knuckles formed on the surface side is formed by allowing a warp to pass over a single upper side weft. For example, as shown in FIGS. 2 (a), (b) and (c), the upper side binding warp (1Ub) passes over the single upper side weft (1U) and the single upper side weft (5U) to form warp knuckles. The upper side warp (2U) also passes over each single weft of the upper side wefts (2U, 4U, 6U, 8U) to form warp knuckles. As shown in FIG. 1, in shafts adjacent to the warp knuckle (.circle-solid./X), at least two other warp knuckles (.circle-solid.X) are arranged in diagonal directions in a planar view. For example, in diagonal directions in a planar view of the warp knuckle (.circle-solid.) formed by allowing the upper side binding warp (Mb) to pass over the upper side weft (3U), the upper side warp (2U) passes over the upper side weft (2U) to form another warp knuckle (X), and the upper side warp (20) passes over the upper side weft (4U) to form another warp knuckle (X). In other words, two warp knuckles are arranged in the diagonal directions. In addition, in diagonal directions in a planar view of the warp knuckle (.circle-solid.) formed by allowing the upper side binding warp (1Ub) to pass over the upper side weft (1U), the upper side warp (2U) passes over the upper side weft (2U) to form another warp knuckle (X), and the upper side warp (2U) passes over the upper side weft (8U) to form another warp knuckle (X). In other words, two warp knuckles are arranged in the diagonal directions.

(21) By sequentially arranging warp knuckles as described above, a herringbone pattern can be formed on the surface layer side of a fabric. By forming the herringbone pattern as shown in FIG. 1, an industrial two-layer fabric without diagonal weave lines can be provided.

(22) In the industrial fabric of the first embodiment, the number of warp knuckles sequentially arranged between peaks forming the herringbone pattern is 3.

(23) A single binding yarn forms a knuckle on the upper layer fabric, and at places adjacent to the knuckle, two warp knuckles are formed in diagonal directions. Thus, an uneven shape generated around a warp knuckle formed by a single binding yarn can be cancelled by the stress relation with two adjacent warp knuckles. Hence, an industrial two-layer fabric that prevents transfer marks from forming on a contact face of paper with the fabric and has excellent surface smoothness and running stability can be provided.

Second Embodiment

(24) FIG. 3 is a design diagram illustrating a complete design of a second embodiment of the industrial two-layer fabric of the present invention. The design diagram includes upper side warps (2U, 3U, 5U, 6U), lower side warps (2L, 3L, 5L, 6L), and two warp pairs including upper side binding warps (1Ub, 4Ub) and lower side binding warps (1Lb, 4Lb) having a binding function. A first warp pair is composed of 1Ub and 1Lb, and a second warp pair is composed of 4Ub and 4Lb. The industrial two-layer fabric of the second embodiment is a 12-shaft fabric. The arrangement ratio of upper side wefts and lower side wefts is 1:1.

(25) Each of the warp knuckles formed on the surface side is formed by allowing a warp to pass over a single upper side weft. For example, as shown in FIGS. 4 (a), (b), (c), (d), (e) and (f), the upper side binding warp (1Ub) passes over the single upper side weft (1U) and the single upper side weft (4U) to form warp knuckles, and the lower side binding warp (1Lb) passes over the single upper side weft (7U) and the single upper side weft (10U) to form warp knuckles. The upper side warp (2U) also passes over each single weft of the upper side wefts (2U, 6U, 8U, 12U) to form warp knuckles.

(26) As shown in FIG. 3, in shafts adjacent to the warp knuckle (.circle-solid.X), at least two other warp knuckles (.circle-solid.X) are arranged in diagonal directions in a planar view. For example, in diagonal directions in a planar view (on the left side in FIG. 3) of the warp knuckle (.circle-solid.) formed by allowing the upper side binding warp (4Ub) to pass over the upper side weft (4U), the upper side warp (3U) passes over the upper side weft (3U) to form another warp knuckle (X), and the upper side warp (3U) passes over the upper side weft (5U) to form another warp knuckle (X). In other words, two warp knuckles are arranged in the diagonal directions. In addition, in diagonal directions in a planar view of the warp knuckle (.circle-solid.) formed by allowing the upper side binding warp (1Ub) to pass over the upper side weft (1U), the upper side warp (2U) passes over the upper side weft (2U) to form another warp knuckle (X), and the upper side warp (2U) passes over the upper side weft (12U) to form another warp knuckle (X). In other words, two warp knuckles are arranged in the diagonal directions. In a diagonal direction in a planar view (on the left side in FIG. 3) of the warp knuckle (X) formed by allowing the upper side warp (2U) to pass over the upper side weft (2U), the upper side binding warp (1Ub) passes over the upper side weft (1U) to form another warp knuckle (.circle-solid.), and in a diagonal direction on the right side in FIG. 3, the upper side warp (3U) passes over the upper side weft (3U) to form another warp knuckle (X). In other words, two warp knuckles are arranged in the diagonal directions.

(27) By sequentially arranging warp knuckles as described above, a herringbone pattern can be formed on the surface layer side of a fabric. In the herringbone pattern of the second embodiment, the upper side binding warp 1Ub passes over the upper side wefts (1U, 4U,) to form two warp knuckles (.circle-solid.); the lower side binding warp 1Lb passes over the upper side wefts (7U, 10U) to form two warp knuckles (.circle-solid.); the upper side binding warp 4Ub passes over the upper side wefts (4U, 7U,) to form two warp knuckles (.circle-solid.); and the lower side binding warp 4Lb passes over the upper side wefts (1U, 10U) to form two warp knuckles (.circle-solid.). These eight warp knuckles correspond to peaks of the herringbone pattern. The industrial fabric of the second embodiment is characterized in that all the eight warp knuckles are formed by binding yarns.

(28) In the industrial fabric of the second embodiment, the number of warp knuckles sequentially arranged between peaks forming the herringbone pattern is 4.

(29) By forming the herringbone pattern as shown in FIG. 3, an industrial two-layer fabric without diagonal weave lines can be provided.

(30) A single binding yarn forms a knuckle on the upper layer fabric, and at places adjacent to the knuckle, two warp knuckles are formed in diagonal directions. Thus, an uneven shape generated around a warp knuckle formed by a single binding yarn can be cancelled by the stress relation with two adjacent warp knuckles. Hence, an industrial two-layer fabric that prevents transfer marks from forming on a contact face of paper with the fabric and has excellent surface smoothness and running stability can be provided.

Third Embodiment

(31) FIG. 5 is a design diagram partly illustrating a surface pattern of a third embodiment of the industrial two-layer fabric of the present invention. In the drawing, the mark .square-solid. indicates a warp knuckle formed by a binding yarn or an upper side warp. The same is applied to fourth and fifth embodiments.

(32) As shown in FIG. 5, the surface pattern of the industrial two-layer fabric of the third embodiment includes eight upper side warps and binding warps.

(33) In the industrial two-layer fabric of the third embodiment, the number of warp knuckles between peaks forming a herringbone pattern is 16, which is twice the number of upper side warps, 8. In other words, the number of warp knuckles sequentially arranged is 16 in total: from the warp knuckle as the peak at the intersection of warp 8 and weft 16, warp 7-weft 15, warp 6-weft 14, warp 5-weft 13, warp 4-weft 12, warp 3-weft 11, warp 2-weft 10, warp 1-weft 9, warp 8-weft 8, warp 7-weft 7, warp 6-weft 6, warp 5-weft 5, warp 4-weft 4, warp 3-weft 3, warp 2-weft 2, to warp 1-weft 1 as the other peak at which the line is inverted in the normal direction to form a zigzag pattern.

(34) By sequentially arranging warp knuckles as described above, a herringbone pattern can be formed on the surface layer side of a fabric. Thus, an industrial two-layer fabric having no diagonal weave lines, giving no transfer marks, and having excellent surface smoothness and running stability can be provided.

Fourth Embodiment

(35) FIG. 6 is a design diagram partly illustrating a surface pattern of a fourth embodiment of the industrial two-layer fabric of the present invention. As shown in FIG. 6, the surface pattern of the industrial two-layer fabric of the fourth embodiment includes six upper side warps and binding warps.

(36) In the industrial two-layer fabric of the fourth embodiment, the number of warp knuckles between peaks forming a herringbone pattern is 3. The number of peaks of the herringbone pattern is four in total: warp 1-weft 1, warp 3-weft 3, warp 4-weft 1, and warp 6-weft 3. Such complete designs are connected vertically and horizontally to form a herringbone pattern in a running direction. Thus, an industrial two-layer fabric having no diagonal weave lines, giving no transfer marks, and having excellent surface smoothness and running stability can be provided.

Fifth Embodiment

(37) FIG. 7 is a design diagram partly illustrating a surface pattern of a fifth embodiment of the industrial two-layer fabric of the present invention. As shown in FIG. 7, the surface pattern of the industrial two-layer fabric of the fifth embodiment includes 12 upper side warps and binding warps.

(38) In the industrial two-layer fabric of the fifth embodiment, the number of warp knuckles between peaks forming a herringbone pattern is 5. The number of peaks of the herringbone pattern is 6 in total: warp 1-weft 4, warp 1-weft 8, warp 5-weft 4, warp 5-weft 8, warp 9-weft 4, and warp 9-weft 8. Such complete designs are connected vertically and horizontally to form a herringbone pattern in a running direction. Thus, an industrial two-layer fabric having no diagonal weave lines, giving no transfer marks, and having excellent surface smoothness and running stability can be provided.

(39) FIG. 8 is a photograph illustrating the result of a surface printing mark test on an industrial two-layer fabric that was produced in accordance with the second embodiment. FIG. 9 is a photograph illustrating the result of a surface printing mark test on a conventional fabric that was produced to have a twill weave pattern.

(40) Black areas are projected areas on the fabric surface. FIG. 9 shows transfer marks that are sequentially arranged in diagonal directions on the industrial two-layer fabric. In contrast, FIG. 8 shows comparatively clear black dots that appear to form a herringbone pattern on the industrial two-layer fabric of the embodiment. On the industrial two-layer fabric of the present invention, no transfer marks are observed in diagonal directions. In other words, it has been revealed that the industrial two-layer fabric of the embodiment achieves such significant effects that dehydration marks are suppressed to be transferred to paper and the surface smoothness is improved without increases in mesh thickness as compared with conventional industrial two-layer fabrics.

DESCRIPTION OF REFERENCE SIGNS

(41) 1 to 12 warp 1 to 30 weft U upper yarn L lower yarn b binding yarn